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Refrigeration Manual: Part 3 - The Refrigeration Load
Refrigeration Manual: Part 3 - The Refrigeration Load
FOREWORD
The practice of refrigeration undoubtedly goes back as far as the history of mankind, but
for thousands of years the only cooling mediums were water and ice. Today refrigeration in
the home, in the supermarket, and in commercial and industrial usage is so closely woven
into our everyday existence it is difficult to imagine life without it. But because of this rapid
growth, countless people who must use and work with refrigeration equipment do not fully
understand the basic fundamentals of refrigeration system operation.
This manual is designed to fill a need which exists for a concise, elementary text to aid
servicemen, salesman, students, and others interested in refrigeration. It is intended to
cover only the fundamentals of refrigeration theory and practice. Detailed information as to
specific products is available from manufacturers of complete units and accessories. Used
to supplement such literatureand to improve general knowledge of refrigerationthis
manual should prove to be very helpful.
Part 3
THE REFRIGERATION LOAD
Section 12. HEAT TRANSMISSION
INDEX OF TABLES
Table 4
Table 5
Table 6
Table 7
Table 7A
Table 8
Table 9
Table 10
Table 11
Table 12
Table 13
Table 14
Table 15
Table 16
Table 17
Table 18
Table 19
Section 12
HEAT TRANSMISSION
The heat gain through walls, floors and ceilings will vary
with the type of construction, the area exposed to a different temperature, the type of insulation, the thickness
of insulation, and the temperature difference between
the refrigerated space and the ambient air.
R total = r1 + r2 + r3
Where r1, r2, and r3 are individual resistances. This
makes the use of r convenient in calculating overall
heat transfer coefficients.
CONDUCTANCE C
Q = U x A x TD
Q = Heat transfer, BTU/Hr
U = Overall heat transfer coefficient
BTU/(hour)(sq. ft.)(F TD)
A = Area in square feet
TD = Temperature differential between
sides of thermal barrier, for
example, between outside design
temperature and the refrigerated
space temperature.
Thermal conductance is similar to thermal conductivity, except that it is an overall heat transfer factor for
a given thickness of material, as opposed to thermal
conductivity, k, which is a factor per inch of thickness.
The definition is similar, BTU/(hour)(square foot of
area)(F TD).
THERMAL RESISTANCE R
Thermal resistance is the reciprocal of conductance, 1/C
in the same way that thermal resistivity is the reciprocal
of conductivity.
THERMAL CONDUCTIVITY k
.25(k) x 2 sq. ft. x 24 hours x 70 TD
Q=
3 inches thickness
= 280 BTU
Since the total heat transferred by conduction varies
directly with time, area, and temperature difference, and
varies inversely with the thickness of the material, it is
readily apparent that in order to reduce heat transfer,
12-1
1 2
= .16 + .80
1 X
R Total = C + k
1
1
U = R Total = 8.75
=.114 BTU/(hour)(sq. ft.)(F TD)
Once the U factor is known, the heat gain by transmission through a given wall can be calculated by the basic
heat transfer equation.
1 X1 X2
R Total = C + k1 + k2
1
U= R Total
Q = U x A x TD
= .114 x 90 sq. ft x 80TD
= 812 BTU/hr
For example, to calculate the U factor of a wall composed of two inches of material having a k1 factor of
12-2
(continued on p. 12-8)
12-3
12-4
12-5
12-6
12-7
12-8
12-9
Section 13
AIR INFILTRATION
Any outside air entering the refrigerated space must be
reduced to the storage temperature, thus increasing the
refrigeration load. In addition, if the moisture content of
the entering air is above that of the refrigerated space,
the excess moisture will condense out of the air, and
the latent heat of condensation will add to the refrigeration load.
Velocity = 100 FPM x
2.83 10
=100 x 2.65 x 7.74
= 138 FPM
8 100
7 x 60
13-1
VENTILATING AIR
per cubic foot of infiltration as given in Table 9. For accurate calculations at conditions not covered by Table
9, the heat load can be determined by the difference
in enthalpy between entering air and the storage room
air conditions. This is most easily accomplished by use
of the psychrometric chart, which will be discussed in
detail in a subsequent section.
13-2
13-3
Section 14
PRODUCT LOAD
HEAT OF RESPIRATION
The product load is composed of any heat gain occurring due to the product in the refrigerated space. The
load may arise from a product placed in the refrigerator
at a temperature higher than the storage temperature,
from a chilling or freezing process, or from the heat of
respiration of perishable products. The total product load
is the sum of the various types of product load which
may apply to the particular application.
14-1
14-2
14-3
14-4
14-5
14-6
Most products are at a higher temperature than the storage temperature when placed in a refrigerator. Since
many foods have a high percentage of water content,
their reaction to a loss of heat is quite different above
and below the freezing point. Above the freezing point,
the water exists in liquid form, while below the freezing
point, the water has changed its state to ice.
Q = W x c x (T1 - T2)
Q = BTU to be removed
W = Weight of the product in pounds
c = Specific heat above freezing
T1 = Initial temperature, F.
T2 = Initial temperature, F. (freezing or above)
14-7
W x c x (T1 - T2)
1000 pounds x .71 specific heat x (42-29)
1000 x .71 x 13
9,230 BTU
= BTU to be removed
= Weight of product in pounds
= Specific heat below freezing
= Freezing temperature
= Final temperature
= W x ci x (Tf - T3)
= 1,000 lbs. x .39 specific heat x (29-0)
= 1,000 x .39 x 29
= 11,310 BTU
Q = W x hif
Q = BTU to be removed
W = Weight of product in pounds
hif = latent heat of fusion, BTU/lb.
BTU
BTU
BTU
BTU
STORAGE DATA
Q = W x hif
= 1000 lbs. x 91 BTU/lb.
= 91,000 BTU
The heat to be removed from a product to reduce its temperature below freezing may be calculated as follow:
Q = W x ci x (Tf - T3)
Q
W
ci
Tf
T3
14-8
14-9
14-10
14-11
14-12
14-13
Section 15
SUPPLEMENTARY LOAD
TOTAL SUPPLEMENTARY LOAD
ELECTRIC MOTORS
Since energy cannot be destroyed, and can only be
changed to a different form, any electrical energy
transmitted to motors inside a refrigerated space must
undergo a transformation. Any motor losses due to friction and inefficiency are immediately changed to heat
energy. That portion of the electrical energy converted
into useful work, for example in driving a fan or pump,
exists only briefly as mechanical energy, is transferred
to the fluid medium in the form of increased velocity, and
as the fluid loses its velocity due to friction, eventually
becomes entirely converted into heat energy.
A common misunderstanding is the belief that no heat
is transmitted into the refrigerated space if an electric
motor is located outside the space, and a fan inside the
space is driven by means of a shaft. All of the electrical
energy converted to mechanical energy actually becomes a part of the load in the refrigerated space.
Because the motor efficiency varies with size, the heat
load per horsepower as shown in Table 16 has different
values for varying size motors. While the values in the
table represent useful approximations, the actual electric power input in watts is the only accurate measure
of the energy input.
HUMAN HEAT LOAD
People give off heat and moisture, and the resulting
refrigeration load will vary depending on the duration of
occupancy of the refrigerated space, temperature, type
of work, and other factors. Table 17 lists the average
head load due to occupancy, but stays of short duration,
the heat gain will be somewhat higher.
15-1
Section 16
EQUIPMENT SELECTION
Once the refrigeration load is determined, together with
the required evaporating temperature and the expected
condensing temperature, a compressor can be intelligently selected for a given application.
HOURLY LOAD
Refrigeration equipment is designed to function continuously, and normally the compressor operating time is determined by the requirements of the defrost system. The
load is calculated on a 24 hour basis, and the required
hourly compressor capacity is determined by dividing
the 24 hour load by the desired hours of compressor
operation during the 24 hour period. A reasonable safety
factor must be provided to enable the unit to recover
rapidly after a temperature rise, and to allow for loading
heavier than the original estimate.
16-1
(A)
Sidewalls:
40 x 8 x 2 = 640 Ft2 x
60TD x 1.9 (Table 7A)
24 Hour Load:
= 72,960 BTU
10 x 8 x 2 = 160 Ft2 x
60TD x 1.9
= 18,240
Ceiling:
40 x 10 = 400 Ft2 x 60TD
x 1.9
= 45,600
Floor:
40 x 10 = 400 Ft2 x 15TD
x 1.9
= 11,400
Heat Transmission
Air Infiltration
Product
Supplementary
Total 24 Hour Load
148,200 BTU
120,270
608,025
62,544
939,039 BTU
2,500 BTU
Desired
TD
Temperature
Relative
(Refrigerant
Range
Humidity
to Air)
25F. to 45F.
90%
8F. to 12F.
25F. to 45F.
85%
10F. to 14F.
25F. to 45F.
80%
12F. to 16F.
25F. to 45F.
75%
16F. to 22F.
10F. and below
15F. or less
675 BTU
1,000 lbs. beans x 9700
BTU/24 Hr/Ton (Table 10)
= 4,850 BTU
Total 24 hour Product Load 608,025 BTU
(D) SUPPLEMENTARY LOAD
200 Watts x 12 hours x 3.41
BTU/Hr
8,184 BTU
51,000 BTU
3,360 BTU
62,544 BTU
COMPRESSOR SELECTION
In order to select a suitable compressor for a given
application, not only the required compressor capacity
must be known, but also the desired evaporating and
condensing temperatures.
Assuming a desired relative humidity of 80%, a 14 TD
might be used, which in a 40F. storage room result
in evaporating temperature of 26F. To provide some
safety factor for line losses, the compressor should be
selected for the desired capacity at 2F. to 3F. below
the desired evaporating temperature.
16-2
COMPONENT BALANCING
Commercially available components seldom will exactly
match the design requirements of a given system, and
since system design is normally based on estimated
peak loads, the system may often have to operate at
conditions other than design conditions. More than
one combination of components may meet the performance requirements, the efficiency of the system
normally being dependent on the point at which the
system reaches stabilized conditions or balances under
operating conditions.
The factors involved in the variation in evaporator capacity are quite complex when both sensible heat transfer
and condensation are involved. For component balancing purposes, the capacity of an evaporator where
both latent and sensible heat transfer are involved (a
wet coil) may be calculated as being proportional to the
total heat content of the entering air, and this in turn is
proportional to the wet bulb temperature. For wet coil
conditions, evaporator capacities are normally available
from coil manufacturers with ratings based on the wet
bulb temperature of the air entering the coil. For conditions in which no condensation occurs (a dry coil) the
evaporator capacity can be accurately estimated on
the basis of the dry bulb temperature of the air entering the coil.
It is now possible to construct balance lines for the compressor and condenser at various ambient temperatures
as shown in Figure 71. For an ambient temperature
of 100F., point A would represent the balance point
if the compressor were operating at a suction pressure equivalent to a 28F. evaporating temperature
and 120F. condensing temperature. At this point the
capacity of the condenser would exactly match that of
the compressor at a 20 TD (condensing temperature
minus ambient temperature). The balance point is determined by the intersection of the 20F. TD condenser
capacity curve with the compressor capacity curve for
Some manufacturers of commercial and low temperature coils publish only ratings based on the temperature
difference between entering dry bulb temperature and
the evaporating refrigerant temperature. Although frost
(continued on p. 16-9)
16-3
16-4
16-5
16-6
16-7
16-8
This type of graphical analysis can be quickly and easily made by using the compressor specification sheet
as the basic chart, and superimposing condenser and
evaporator capacity curves.
Original Revised
System System
Ambient Temperature 100F.
100F.
Air Entering Evaporator 40F. 40F.
Refrigerant Evaporating
Temp. 26F. 27F.
Condensing Temperature 120F.
115F.
Capacity at 100F. Ambient
and 40F. Entering Air,
BTU/hr. 59,000
53,000
(continued on p. 16-11)
16-9
16-10
Note that although the compressor capacity was decreased by 1/6 or 16 2/3%, the net system capacity
decreased only about 10%. Since the condenser and
evaporator were unchanged, the compressor could
operate at more efficient conditions, with decreased
condensing pressure and increased suction pressure.
The most accurate means of determining the refrigeration load is by calculating each of the factors contributing
to the load as was done in the previous example. However, for small walk-in coolers, various types of short
cut estimating methods are frequently used.
16-11
Table 18
Table 19
16-12
16-13